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Keeping Immersed Tunnels Watertight for 120 Years Contents Contents CASE STUDIES

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Keeping Immersed Tunnels Watertight for 120 Years Contents Contents CASE STUDIES TRELLEBORG MARINE AND INFRASTRUCTURE Keeping Immersed Tunnels Watertight for 120 Years Contents Contents CASE STUDIES: TRELLEBORG’S TUNNEL TIMELINE 6 CONNECTING DENMARK AND SWEDEN 8 ØRESUND LINK, DENMARK - SWEDEN SECOND CHANCE AT INCREASING ACCESSIBILTY 10 SECOND COEN TUNNEL, AMSTERDAM, THE NETHERLANDS REDUCING CONGESTION, SEALING SAFETY 12 MIDTOWN TUNNEL, HAMPTON ROADS, USA A FIRST FOR MEXICO 14 COATZACOALCOS TUNNEL, COATZACOALCOS, MEXICO UNDERWATER CONNECTION IN STOCKHOLM 16 SÖDERSTRÖM TUNNEL, STOCKHOLM, SWEDEN THE WORLD’S LONGEST LINK 18 HONG KONG-ZHUHAI-MACAU BRIDGE, HONG KONG - CHINA IMMERSED IN RAIL 20 SHA TIN-CENTRAL IMMERSED TUNNEL, HONG KONG - CHINA A PORT UNDER PRESSURE 22 MARIEHOLM TUNNEL, GOTHENBURG, SWEDEN Keeping Immersed Tunnels Watertight for 120 Years Sealed for success: time-tested sealing systems in action. Growing urbanization into major cities means sealing systems are one of the few solutions our current infrastructure is under intensifying that protect against water ingress and extreme pressure as people migrate from one place movements. The flexibility, durability, and to another and need access to new locations. 120-year expected lifespan of our polymer The impact of climate change and ever-rising solutions place us as the leading partner for water levels also means many environments the design and manufacture of reliable sealing are at a much greater risk of flooding and systems that can stand the test of time and seismic movements, which existing systems, support the long-term integrity of new structures. such as immersed tunnels simply can’t withstand. It’s now more important than ever Take a look at some of the most exciting that we modernize existing structures and build projects we’ve been part of and delve deeper new ones that can endure high water pressure into our tailor-made engineered solutions and make even the most extreme environments in some of the most technically complex more accessible to our growing population. and challenging environments. As the world’s leading supplier of total sealing systems for immersed tube, bored and cut and cover tunnels for over 50 years, Trelleborg’s 4 5 Sealed A timeline of Trelleborg’s recent for success tunnel projects DENMARK - SWEDEN NETHERLANDS USA MEXICO SWEDEN HONG KONG - CHINA HONG KONG - CHINA SWEDEN Connecting Denmark Second chance at Reducing congestion, A first for Mexico Underwater connection The worlds longest link Immersed in rail A port under pressure and Sweden increasing accessibility sealing safety in Stockholm Trelleborg supplied For the 1,270m Trelleborg supplied For the first-ever Trelleborg supplied 34 of Trelleborg’s For the Sha Tin to Trelleborg’s Gina a specially designed immersed tunnel its Gina gasket and immersed tunnel seals using a Gina gaskets and over Central Link tunnel, gaskets and Omega Gina gasket to seal aimed at relieving Omega seals to in Latin America, unique prestress 250 Omega seals Trelleborg’s Gina gaskets seals were used tunnel sections, as congestion in securely connect the Trelleborg developed method for the were used to seal were supplied as closed between the sectional part of a 16km long Amsterdam, 11 tunnel elements for a new Gina gasket 6km-long, two-track the tunnel elements rectangular frames, as elements of the bridge/tunnel project Trelleborg’s high- the 1,280m immersed with more deformation tunnel connecting for the world’s well as Omega seals, to immersed Marieholm between Denmark performance seals tunnel near the site of capacity, providing Riddarholmen and longest deepwater secure the 11 concrete tunnel, alongside and Sweden. secured each tunnel the largest US naval secure connections for Söderström, ensuring immersed tunnel. elements and ensure water stops at the element, protecting base in Portsmouth, each tunnel element. the tunnel components they were watertight. construction joints, to against water ingress. Virginia. were watertight. ensure watertightness. Tunnel opened in 2000 Tunnel opened in 2013 Tunnel opened in 2016 Tunnel opened in 2017 Tunnel opened in 2017 Tunnel opened in 2019 Set to open in 2022 Tunnel opened in 2020 6 7 Connecting Denmark and Sweden Øresund LINK Denmark, Sweden Problem: For many years, the Strait of Øresund Solution: The Gina gasket was vulcanized was a barrier to transporting goods and people on site due to logistical challenges. The between Denmark and Sweden. To improve vulcanization was implemented in a container ease of access, and increase commercial under a conditioned environment. opportunities, a better link was needed between the two cities, and so construction began on A Gina gasket with a hollow soft nose was the world’s longest cable-stayed bridge. required to initially seal against an uneven concrete surface and required for a low reaction Challenge: A 3.5km long immersed tunnel force and a relatively large initial compression. was constructed to bridge a connection between Trelleborg developed Denmark and Sweden. The tunnel included a bespoke Gina gasket 20 precast concrete elements, each weighing 55,000 tonnes, which connect the artificial to initially seal against peninsula at Kastrup to the man-made island an uneven concrete surface in Strait of Øresund. and provide a low reaction force, as well as a relatively large initial compression. 8 9 Second chance at increasing accessibility Second Coen Tunnel Amsterdam, The Netherlands Problem: A growing population and demand the design had to be changed to make a larger for access to the city of Amsterdam placed gasket. Segment joints with waterstop profiles existing infrastructure under immense pressure embedded also had to be enlarged to cope with as it competed with new safety regulations possible higher deformations. and more than 120,000 cars every day. Solution: As the largest immersed tunnel A second Coen tunnel was constructed containing in the Netherlands, it was essential that each three fixed lanes and two reversible lanes, to element was securely bonded to protect the alleviate congestion and improve access to the tunnel against water ingress. Trelleborg’s greater Amsterdam area. The 1,270m tunnel high-performance seals secured each tunnel was built in combination with a new highway element making sure they are watertight Trelleborg’s high-performance connection – the Westrandweg – as part of a and remain functional, even when faced seals secured each tunnel series of infrastructure enlargement projects, with natural ground movement. and operates alongside the existing immersed element making sure they are Coen tunnel under the North Sea Canal. watertight and remain functional, even when faced with natural Challenge: There was a higher calculated risk ground movement. for a sinking ship hence the Gina gasket was required to be designed to face this issue and 10 11 Reducing congestion, sealing safety Midtown Tunnel Hampton Roads, USA Problem: Congestion is a growing concern The tunnel had to be built without interference Omega seal consists of multiple layers of styrene in nearly all major cities, but in Portsmouth, to the ship movements so no delay in delivery butadiene rubber and nylon inlayers to enhance Virginia, this was even more problematic. of our gaskets was allowed. durability and keep the tunnel watertight. Combining the two seals enables the transfer Located across the Elizabeth River from Norfolk Solution: Trelleborg assisted with the creation of hydrostatic loads and movements between – the site of the largest US Navy base – the of a second midtown tunnel that sits parallel the tunnel ends, caused by soil settlement, pre-existing Midtown tunnel became a constant to the existing tunnel, which aimed to improve creep of concrete and temperature effects. gridlock of traffic, carrying a million vehicles per travel times and prevent water ingress from month. When military personnel needed to reach the Elizabeth River. Trelleborg’s Gina gasket their naval base, the volume of traffic had the and Omega seals potential to cause critical delays. An innovative The 1,280m immersed tunnel consisted securely connected each solution was needed to relieve bidirectional of 11 rectangular concrete tunnel elements, tunnel segment together traffic and, above all, promote safety. each of which was fitted with Trelleborg’s to prevent water ingress Gina gaskets and Omega seals to prevent Challenge: Hydrostatic loads and movements water ingress. and provided flexibility between the tunnel ends, caused by soil for transfer of settlement, creep of concrete, temperature The Gina gasket is made from natural rubber, hydrostatic loads. effects and earthquakes. connecting each segment together, and the 12 13 A first for Mexico Coatzacoalcos Tunnel Coatzacoalcos, Mexico Problem: The development of industrial Solution: At 1.1km long and 35 meters complexes on the east of the Coatzacoalcos underwater, the Coatzacoalcos tunnel was the River meant that the existing bridge with two first-ever immersed tunnel in Latin America. It was lanes and a single track was not sufficient built using an immersion technique, where each for the sheer volume of traffic traveling through element is prefabricated in a dry dock before it. With more than 18,000 vehicles and being towed to the tunnel site, to minimize the 8,000 pedestrians crossing the river between impact on the environment during construction. Coatzacoalcos and Allende every day, it was essential that a new route was developed Five monolithic elements were used to build the to reduce congestion and improve connections tunnel, reducing the risk of damage and leakage Trelleborg developed between the cities. caused by earthquakes. Finding seals that would a new Gina gasket be flexible enough to work with the monolithic with more deformation Challenge: Gina gaskets featuring the elements and protect the tunnel from water largest cross sections ever had to be ingress was critical. Trelleborg developed a new capacity to provide produced, which created logistical challenges. Gina gasket with more deformation capacity unrestricted movement The larger cross sections were required to to allow for unrestricted movement and secure and secure connections provide enough resilience of the seal during connections between each element, while between each element.
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